Cswip 3 2 Notes 1

EXAMINATION
Examination in 5 (or 8) Parts

(Each part has a 70% pass mark)
1. Technical Paper (1h 15min)
• 6 Questions given (4 answers required)
• Question #1 must be answered
• Answer 3 other questions from the remaining 5 questions
2. Interpretation of Welding Symbols (1h)
• Engineering drawing has welding symbols for 12 joints
• Interpret the symbols & comment on any errors or inconsistencies
3. Fracture Face Examination (1h)
• Examine fracture faces of 2 specimens & interpret modes of failure
4. NDT Reports (1h)
• Scrutinise 3 NDT Reports & list all errors and all omissions
5. Oral (~ 10 to 15 min)
• 1 Question: - subject will be related to supervision of welding inspectors or to safety
matters
Copyright © 2005, TWI Ltd 1 World Centre for Materials Joining Technology
EXAMINATION
Examination in 5 (or 8) Parts
(Each part has a 70% pass mark)
If a candidate for the Senior Welding Inspector Examination does not
hold a recognised qualification in Radiographic Interpretation
(a CSWIP or PCN Certificate) he is required to sit 3 additional
examination parts, namely: -
6. Radiographic Interpretation (1h 30min)

• 6 dense metal welds - steel
7. Multi-Choice Radiographic Theory Paper (30min)

• 30 questions
8. Radiographic Density & Sensitivity (1h)

• Densitometer calibration using a Density Strip
• Sensitivity calculations for 5 welds
THE
THE SENIOR
SENIOR WELDING
WELDING INSPECTOR
INSPECTOR
A Senior Welding Inspector may be ‘Senior’ through being

put in charge of a team of Welding Inspectors.
In this role he may have a predominantly managerial role

that requires organising and supervising their work and so
may have title of ‘Team Leader’ or ‘Supervisor’.
In other circumstances he may have a more technically

demanding role that requires detailed knowledge of
particular activities.
The CSWIP Senior Welding Inspector Course is intended to

cover aspects of both these roles.
THE
THE SENIOR
SENIOR WELDING
WELDING INSPECTOR
INSPECTOR
TYPICAL REQUIREMENTS - TECHNICAL KNOWLEDGE
Welding Technology
(Welding Inspector ………. plus)
• NDT Techniques
( ability to carry out / interpret)
• Codes/Application Standards
(ability to interpret)
• Planning Systems
(ability to understand and also supply inspection
scheduling to project schedule)
• Quality Assurance
(ability to plan & carry out some auditing)
THE
THE SENIOR
SENIOR WELDING
WELDING INSPECTOR
INSPECTOR
LEADERSHIP / SUPERVISION
A Supervisor is a person who has been given authority and

responsibility for: -
• planning the work of others
• controlling this work
A Supervisor is a ‘man in the middle’ between operators and

management and subject to pressures from both directions
THE
THE SENIOR
SENIOR WELDING
WELDING INSPECTOR
INSPECTOR
LEADERSHIP
Is leadership an ability that a person is ‘born’ with or

can it be acquired !!!!!! ?????
• Personality is very influential - hence leadership

sometimes considered to be in the ‘genes’ and a person
referred to as ‘a born leader’
• Ability to be a good leader can be improved by
experience & from knowledge of management
techniques through training
THE
THE SENIOR
SENIOR WELDING
WELDING INSPECTOR
INSPECTOR
TYPICAL REQUIREMENTS - LEADERSHIP SKILLS /
ABILITY
Complex mixture of skills & attitudes - such as ……
• being prepared to accept responsibility

• willing to direct the work of others
• willing, and able, to delegate tasks to others
• having a commitment to one’s staff
• able to solve / overcome problems (from greater & wider experience)
• able to do all (or most of) the work done by one’s staff
• able to communicate - ‘downwards’ & ‘upwards’ within the Company
THE
THE SENIOR
SENIOR WELDING
WELDING INSPECTOR
INSPECTOR
What Makes a Good Leader / Supervisor ?
Qualities that are associated with a Good Supervisor are: -

• has good technical skill & knowledge and good at solving problems
• has ability to quickly determine priorities
• is intelligent and confident
• shows good judgement
• has enthusiasm for work and is usually cheerful & optimistic
• sets a good example at work - high standards - leads by ‘example’
• has no ‘favourites’ and able to apply discipline fairly
• is approachable - good listener - and prepared to consult staff
• informs staff of important decisions affecting them and ‘backs his team’
• is able to identify needs of ‘team’ and obtain equipment and training
• good at planning and delegation
THE
THE SENIOR
SENIOR WELDING
WELDING INSPECTOR
INSPECTOR
Morale & Motivation of Staff
What are the signs of low morale in the work place ?

Compile a List
How can morale be raised ?

Apply good leadership qualities - list actions
PRODUCTION
PRODUCTION PLANNING
PLANNING
PRESSURE VESSEL FABRICATION
T = Tier
N3
H = Head
N = Nozzle
T1 T2 T3
N1 H1 H2
W1 W2
S1 N2 S2
W = Wrapper plate
S = Saddle
PRODUCTION
PRODUCTION PLANNING
PLANNING
PRESSURE VESSEL: Typical Production Sequence
1. Prepare drawings & material list 11. Fit & weld - N1 + H1
2. Order materials - plate 12. Mark out, cut & roll wrapper plates
3. “ “ - fittings
13. Weld W1 & W2 to shell plates
4. “ “ - heads
14. Fit & weld nozzles N2 & N3
5. “ “ - welding
consumables 15. Cut, assemble & weld saddles S1 & S2
6. Mark out, cut & roll shell plates
16. Fit & weld S1 & S2 to W1 & W2
7. Weld longitudinal seams
17. Carry out all final inspection
8. Fit & weld - T3 to H2
18. Pressure test
9. “ “ - T2 to (T3 H2)
19. Blast & paint
10. “ “ - N1 + H1
20. Deliver
PRODUCTION
PRODUCTION PLANNING
PLANNING
PRESSURE VESSEL: Typical Production Sequence
Bar Chart or Gantt Chart
OPERATION
12
14
21
25
26
10
11
13
15
16
17
18
19
20
22
23
24
27
28
29
30
1
2
3
4
5
6
7
8
9
1 Drawings
2 Material procurement - plate
3 - fittings
4 - heads
5 - welding
6 consumables
Mark, cut & roll shell plates
7 Weld longitudinal seams
8 Fit & weld T3 to H
9 Fit & weld T2 to T3H2
10 Fit & weld N1 to H1 - - - - - - -
11 Fit & weld N1H1 to T2T3H2
12 Cut & roll W1 & W2 - - - - - - - - -
13 Weld W1 & W2 to shell
14 Fit & weld N2 & N3
15 Cut, assemble & weld S1 & S2 - - - - - - - - - - - -
16 Fit & weld S1 & S2 to W1 & W2
17 Complete final Inspection
18 Pressure test
19 Shot blast & paint
20 Deliver
Can use forward or reverse-schedule planning

Welding Procedure Qualification
A Preliminary Welding Procedure Specification (pWPS) is written for each test weld required
• Welder makes a test weld in accordance with the pWPS

• Welding Inspector records all welding details used for making the test weld (‘as-run’ details)
(EN standard states that an Independent Examiner or Examining Body or a Third Party
Inspector’ may be required to monitor the qualification process)
Finished test weld is subjected to NDT by the specified methods

(EN Standard requires visual, MT or PT & RT or UT)
• Test weld subjected to destructive testing according to specified methods

• Application Standard or Client may require additional tests such as impact tests, hardness
tests (for some materials - corrosion tests)
• Welding Procedure Qualification Record (WPQR) prepared giving range of qualification

allowed by the Welding Standard (EN or ASME IX)
• WPQR ‘package’ submitted to Independent Examiner for endorsement (& usually to Client)
Welder Qualification
A WPS is written for a each test weld required
• Welder makes a test weld in accordance with the WPS

• Welding Inspector checks that weld is made according to the WPS requirements
(EN standard states that an Independent Examiner or Examining Body or a Third Party
Inspector’ may be required to monitor the qualification process)
Finished test weld is subjected to NDT by the specified methods

(EN Standard requires visual, MT or PT & RT or UT)
• Test weld may need to be destructive tested for certain materials or welding processes
• A Welder Qualification Certificate is prepared giving range of qualification allowed by the

Welding Standard (EN or ASME IX)
• The Welder Qualification certificate is submitted to Independent Examiner for endorsement
Destructive
Destructive Testing
Testing
WELD PROCEDURE QUALIFICATION TESTING (example)
1 2 3 4 5
SPECIMEN TYPE POSITIONS
macro + hardness 1, 9, 11
pipe diameters 6 transverse tensile 2, 8, 10, 12
12 7
11 > 323.9mm Charpy – weld metal 3, 5, 6
8 Charpy – fusion line 4, 7
10 9
Destructive
Destructive Testing
Testing
QUANTITATIVE TESTS & QUALITATIVE TESTS
QUANTITATIVE TESTS
• for measuring a ‘quantity’ ( ‘quantity’ = a mechanical property )
• typical mechanical tests - tensile test
- hardness test
- Charpy V-notch test (& CTOD)
QUALITATIVE TESTS
• for assessing joint ‘quality’ (‘quality’ = good fusion & free from defects)
• typical qualitative tests - bend tests
- macro examination
(micro examination for some metals)
- fillet fracture & nick-break tests
Destructive
Destructive Testing
Testing
Tensile Testing - Transverse Tensile Test
gauge
length
weld
Position of failure not usually in weld metal but in base material or HAZ
TEST OBJECTIVE
To measure the Tensile Strength of the welded joint
RESULTS
Satisfactory if Tensile Strength greater than min. specified for base metal
(Some standards accept 95% of base material Tensile Strength)
Destructive
Destructive Testing
Testing
Tensile Testing: All-Weld Tensile Test
from WPQ test piece electrode classification test piece
gauge length: all weld metal
TEST OBJECTIVE
To measure Yield Strength & Tensile Strength of weld metal
(% Elongation also measured & usually also % Reduction of Area)
RESULTS
Satisfactory if all values are not less than minimum specified for base
metal (or required by desig) at ambient or at elevated temperature
Destructive
Destructive Testing
Testing
MECHANICAL TESTING: Charpy V-notch Test Positions
For each notch position 3 specimens are tested . May need to take test pieces
from weld metal, fusion line, fusion line + 2, fusion line + 5 from both weld
faces and from root - total of 36 tests
weld metal (surface)
weld metal (root)
fusion line + 5mm

fusion line fusion line + 2mm
Destructive
Destructive Testing
Testing
MECHANICAL TESTING: Charpy V-notch Impact Testing
TEST OBJECTIVE
To measure the impact
toughness of each
region of the weld joint
(weld metal, HAZ &
base metal) at a
specified temperature
that is related to the
service conditions
RESULTS
Satisfactory if all
values are not less the
minimum specified by
the Application
Standard
Welding
Welding Technology
Technology
HAZ TOUGHNESS
unwelded ‘degraded’ HAZ
Toughness fine grained
steel
Charpy V-
notch energy
no significant
(Joules) change in HAZ
toughness if
HAZ toughness transition
moderate heat
temp. has shifted to a
input used
higher temperature
good toughness
in steel at (caused by high heat input
design temp. welding)
low toughness
in HAZ at
design temp.
design temperature Impact Test Temperature
Welding
Welding Technology
Technology
THE HEAT AFFECTED ZONE (HAZ)
Maximum
Temperature solid solid-liquid transition zone
weld
metal grain growth zone
recrystallised zone
partially transformed zone
tempered zone
unaffected base
material
Destructive
Destructive Testing
Testing
MECHANICAL TESTING: Hardness Testing
usually the hardest region
~1.5 to 3mm
fusion line
(fusion HAZ HAZ
boundary)
HARDNESS TEST METHODS

Vickers example 248 HV10 Rockwell
example Rc 22 Brinell
example 220 BHN-W (not usually used on macro sections)
TEST OBJECTIVE To measure the max. hardness in the weld joint

(always in HAZ for steels)
RESULTS Satisfactory if no values are above the max.
specified by the Application Standard
Welding
Welding Technology
Technology
HAZ Hardness of Carbon-Manganese Steels
HAZ
intermediate heat-input will
Hardness give satisfactory hardness
low heat-input
welding tends to
give a high HAZ
hardness
high heat-input
welding tends to
give a softer HAZ
fast Rate of Cooling of HAZ slow
Welding
Welding Technology
Technology
HAZ Hardness of Low-Alloy Steels
(such as the higher Cr-Mo grades)
HAZ
Hardness
low heat-input welding high heat-input welding
HAZ hardness always high (> ~ 400 HV)
fast cooling Time to Cool slow cooling
Destructive
Destructive Testing
Testing
QUALITATIVE TESTS: Bend Tests
for joint thicknesses

< ~ 12mm
face in tension = face bend root in tension = root bend
for joint thicknesses

> ~ 12mm
full thickness of joint in tension = side bend
Destructive
Destructive Testing
Testing
QUALITATIVE TESTS: Fillet Fracture & Nick Break Tests
Tests are used instead of radiography or ultrasonic examination to show

• that satisfactory fusion has been achieve
• that the weld is has no defects
FILLET FRACTURE NICK-BREAK
machined slot
force machined slot
fracture from root
PWHT
• Steels are given a PWHT to reduce residual stresses caused by
welding [and also to temper (soften) the hardest regions of the HAZ]
• The main benefit of reducing residual stresses is to improve
resistance to brittle fracture - explained as follows: -
• Residual stresses can be higher than the max. allowed design stress
and are powerful driving forces for propagating flaws (usually cracks)
• In the as-welded condition, the steel joint has a lower tolerance to
flaws that may become initiation points for brittle cracks
• A crack that could cause brittle fracture is called a ‘critical’ crack
• The size of a critical crack depends on the material toughness and
total stress that the crack experiences in the joint (design + residual)
• An as-welded joint may only be able to tolerate a small critical crack
- possibly so small that it could be missed by RT or UT
• When residual stresses are removed, a critical crack should be so big
that it could not be missed during NDT and so would be repaired
PWHT
Removal of Residual Stress
Cr-Mo steel - typical • At PWHT temp. the yield

Yield 500
strength of steel reduced so
Strength
that it it is not strong
(N/mm2 ) 400
C-Mn steel - typical enough to give restraint.
300
• Residual stress reduced to
very low level by straining
(typically < ~ 0.5% strain)
200
100
100 200 300 400 500 600 700

Temperature (°C)
PWHT
Other Benefits of PWHT
• The toughness of the HAZ may be improved - particularly for the more
hardenable low alloy steels & improves brittle fracture resistance
• Removal of residual stress will give steels resistance to stress
corrosion cracking in certain media - for example in sour oil/gas, in
ammonia or in contact with nitrates and chlorides
• It enables a welded component to be machined to accurate tolerances
that may otherwise be impossible due constant ‘re-balancing’ of tensile
and residual stresses when metal is removed during machining. This
may be referred to as a stabilising* PWHT
(* not to be confused with stabilised when referring to stabilising stainless steels

by alloying additions of Nb or Ti)
PWHT
PWHT Procedures - Basic Requirements
A PWHT should specify the following: -
• The max. heating rate
– usually from 300 or 400°C depending on Code or item to ensure temp.
gradients are not excessive (up to ~ 200°C/h max. may be allowed)
– large temp. gradients cause high stresses which may give cracking or
distortion
• The ‘soak’ temperature
– depends on steel type and usually specified by Code (~550 to ~750 °C )
• The ‘soak’ time

– to ensure full thickness, and whole item, is at soak temp.
– Codes typically require 1h per 25mm of max. joint thickness
• The max. cooling rate

– usually to 400 or 300°C - same reasons as for heating rate control
PWHT
PWHT Procedures -Additional Considerations
Before a PWHT commences it is necessary to: -
• Decide the number of thermocouple attachments and their positions
– so that the temperature of the whole component is monitored
• If the item needs to be given any additional support

– to avoid distortion due to self-weight because it is relatively weak at the
soak temp.
For Localised PWHT
Need to also specify: -
• The width of the heated band
– to ensure that residual stresses at a distance from the weld are removed
• The width of the temp. ‘decay’ bands beyond the heated zone
– to ensure high stresses are not produced by large temperature gradients
Post Weld Heat Treatment
Localised PWHT
PWHT procedures also need to also specify: -
• The width of the heated band
– to ensure that residual stresses at a distance from the weld are removed
– should be specified by Code
• The width of the temp. ‘decay’ bands beyond the heated zone
– to ensure high stresses are not produced by large temperature gradients
– should be specified by Code - usually same width as heated band
• The position of the thermocouples to monitor the width of heated

bands and the temp. gradient in the decay bands
temp. temp.
heated band
decay decay
pipeline weld
Cracking in Weld Joints
RE-HEAT CRACKING
• Cracking that occurs when weld joints in certain steels when they are
being heated to their PWHT temperature or are put into elevated temp.
service without PWHT
( this gives this type of cracking the name ‘re-heat’ )
• Susceptible PWHT temp.range ~ 500 to ~ 650°C or service 350 - 550 °C
• Cracking occurs in the HAZ - usually in the zone that has the largest
grain size (the ‘grain growth zone nearest to the fusion line)
grain growth zone
Cracking Mechanisms
RE-HEAT CRACKING
Re-heat cracking occurs because: -
• some strengthening of the steel occurs during heating to the PWHT
temp. (or if in as-welded condition while in service at an elevated temp.)
• strengthening occurs by carbide formation
- steels with Vanadium, Chromium and Molybdenum are most
susceptible because these elements are strong carbide formers
• the carbides & nitrides strengthen the grains so that relief of residual
stresses takes place by all the strain concentrating at the weaker grain
boundaries
• if the steel contains certain levels of impurities (such as Tin, Arsenic
& Phosphorus) they concentrate at the grain boundaries and reduce
their rupture strength
• the presence of large grains in the HAZ means that the impurities are
more concentrated and such regions become the most sensitive to
cracking
Cracking Mechanisms
AVOIDING RE-HEAT CRACKING
The risk of re-heat cracking can be minimised by: -
• using steel that has very low impurity levels
• various formulas have been developed to relate sensitivity to cracking
to levels of impurities
• for particularly sensitive steels (usually those with higher Vanadium)
ensure that: -
– weld bead positions and heat input are controlled to give a fine
grained HAZ (temper-beading)
– avoid stress concentrations - poor fit-up and sharp weld toes
– heat through the sensitive temperature range quickly during PWHT
Quenched & Tempered Steels
Q & T STEELS
• Steels that are strengthened by rapid cooling from an elevated
temperature (quenching)
• Quenching temperature depends on steel composition but typically
~900°C
• Steels are very strong in the quenched condition but ductility and
toughness usually too low for any application
• Tempering reduces the as-quenched strength and gives ‘usable’ ductility
and toughness
• Tempering temperatures typically ~550 to 760°C
• Strengthening by quenching is achieved by certain alloying additions that
allow the stronger phases (martensite & bainite) to form (rather than the
ferrite)
• The % of the alloying elements that allow strengthening must be high
enough to allow the stronger phases to form through the full thickness
• For some steels, the alloying levels need to be higher in thick sections to
ensure ‘through- hardening’
EXAMPLES of Q & T STEELS
Typical Mechanical Properties
STEEL TYPE C Si Mn Cr Mo Ni Nb V Yield / 0.2%PS Tensile Strength Elongation
(N/mm2) (N/mm2) (% on 50mm)
AISI 4130 water quenched & tempered at 595 to 480°C
UNS G41300 - 0.40 0.8 (100mm round section)
W. Nr. 1.7218 0.04 0.60 1.1 - - -
540 to 655 703 to 800 20 to 25
ASTM A 505, 646
0.28 0.15
AISI 8630 0.33 0.25 water quenched & tempered at 595 to 480°C
UNS G86300 0.15 0.70 0.40 0.40 (100mm round section)
W. Nr. 1.6545 0.30 0.90 0.60 0.70 - - 495 to 595 660 to 780 21 to 26
ASTM A 322, 331, 505
AISI 4140 oil quenched & tempered at 650 to 540°C
UNS G41400 0.70 0.80 0.15 (100mm round section)
W. Nr. 1.7225 1.00 1.10 0.25 - - - 580 to 685 772 to 883 19 to 23
ASTM A 322, 331, 505, 519, 646
0.38 0.15
AISI 4340 0.43 0.30 oil quenched & tempered at 650 to 540°C
UNS G43400 0.60 0.70 0.20 1.65 (100mm round section)
W. Nr. 1.6565 0.80 0.90 0.30 2.00 - -
786 to 1000 924 to 1138 16 to 20
ASTM A 332, 505, 519, 547, 646
Other Mechanical Properties

STEEL TYPE C Si Mn Cr Mo Ni Nb V N Yield / 0.2%PS Tensile Strength Elongation
(N/mm2) (N/mm2) (% on 50mm)
A 335-P91 Al
X10CrMoVNb9-1 0.08 - 0.30 8.00 0.85 - 0.06 0.18 0.030 - = 415 585 = 22
(steel number 1.4903) 0.12 0.50 0.60 9.50 1.05 0.40 0.10 0.25 0.070 0.040
12CrMoV11-1 0.17 0.30 10.0 0.80 0.30 - 0.20 - - = 500 700 -850 = 16
(steel number 1.4922) 0.23 0.40 1.0 12.5 1.20 0.80 0.35
0.10 0.10 0.30 8.50 0.90 0.20 0.06 0.15 0.050 W
A 335-P911 0.13 0.30 0.60 9.50 1.10 0.40 0.10 0.25 0.080 0.90
1.10 = 440 = 620 = 22
Typical Chemical Composition Typical Mechanical Properties (t=25mm)

STEEL TYPE Yield/0.2%PS Tensile Strength Elongation
C Si Mn Cr Mo Ni Nb V Ti Al Other (N/mm2) (N/mm2) (% on 50mm)
WELDOX 700 - - - - - - - - - - N (min) 0.0015
0.20 0.60 1.60 0.70 0.70 2.0 0.04 0.09 0.04 0.015 B (max) 0.005 = 700 780 - 930 = 18
WELDOX 900 - - - - - - - - - - N (min) 0.0015
0.20 0.50 1.60 0.70 0.70 2.0 0.04 0.06 0.04 0.018 B (max) 0.005 = 900 940 - 1110 = 16
WELDOX 960 - - - - - - - - - - N (min) 0.0015
0.20 0.50 1.60 0.70 0.70 2.0 0.04 0.06 0.04 0.018 B (max) 0.005 = 960 980 -1150 = 16
WELDOX 1100 - - - - - - - - - - N (min) 0.0015
0.21 0.50 1.40 0.80 0.70 3.0 0.04 0.08 0.02 0.020 B (max) 0.005 = 1100 1250 - 1550 = 12
WELDOX is a registered Trade Name of SSAB Oxelosund
Chemical compositions and tensile properties of some HSLA steels used for structural applications
Welding of Q & T Steels
• Alloying additions used to achieve strengthening also will give
hardening of the HAZ
• Higher HAZ hardness give higher risk of cracking and the need
to always use low Hydrogen welding processes and also the need
to use pre-heat for most grades
• Higher HAZ hardness usually mean that many of these steels
require PWHT to improve resistance to brittle fracture
• Careful control of heat input - not too high - may be needed for
some steel types to avoid softening of the HAZ and loss of
strength
• For the highest strength grades there may be difficulty in
achieving matching strength weld metal that has good
toughness and ductility
Pre-Heat & Interpass Temperature
Pre-Heat Temperature
• Applied to reduce risk of cracking - helps to allow H to escape from
the weld joint and can reduce hardness of HAZ for some steels
• Pre-heat temperature should be checked on both sides of the joint
at a distance of at least 75mm from joint edge
• Pre-heat should be checked on the other side from the pre-heated
side - if access allows
• If hand held gas pre-heating is used, temp. should be checked a
short time after the heating torch has been removed
Interpass Temperature
• This is the temp. at the position that the welder will re-start
welding in a muti-run weld
• Temperature should be measured on the steel as close as practical
to the re-start position (it can be taken on the weldat that point)

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EXAMINATION

Examination in 5 (or 8) Parts

6. Radiographic Interpretation (1h 30min)

7. Multi-Choice Radiographic Theory Paper (30min)

8. Radiographic Density & Sensitivity (1h)

A Senior Welding Inspector may be ‘Senior’ through being

In this role he may have a predominantly managerial role

In other circumstances he may have a more technically

The CSWIP Senior Welding Inspector Course is intended to

A Supervisor is a person who has been given authority and

A Supervisor is a ‘man in the middle’ between operators and

Is leadership an ability that a person is ‘born’ with or

• Personality is very influential - hence leadership

• being prepared to accept responsibility

Qualities that are associated with a Good Supervisor are: -

Morale & Motivation of Staff

What are the signs of low morale in the work place ?

How can morale be raised ?

Can use forward or reverse-schedule planning

• Welder makes a test weld in accordance with the pWPS

Finished test weld is subjected to NDT by the specified methods

• Test weld subjected to destructive testing according to specified methods

• Welding Procedure Qualification Record (WPQR) prepared giving range of qualification

A WPS is written for a each test weld required

• Welder makes a test weld in accordance with the WPS

Finished test weld is subjected to NDT by the specified methods

• A Welder Qualification Certificate is prepared giving range of qualification allowed by the

SPECIMEN TYPE POSITIONS

- fillet fracture & nick-break tests

from WPQ test piece electrode classification test piece

gauge length: all weld metal

weld metal (surface)

weld metal (root)

fusion line + 5mm

HARDNESS TEST METHODS

TEST OBJECTIVE To measure the max. hardness in the weld joint

fast Rate of Cooling of HAZ slow

low heat-input welding high heat-input welding

HAZ hardness always high (> ~ 400 HV)

fast cooling Time to Cool slow cooling

for joint thicknesses

face in tension = face bend root in tension = root bend

for joint thicknesses

full thickness of joint in tension = side bend

Tests are used instead of radiography or ultrasonic examination to show

FILLET FRACTURE NICK-BREAK

fracture from root

Removal of Residual Stress

Cr-Mo steel - typical • At PWHT temp. the yield

100 200 300 400 500 600 700

(* not to be confused with stabilised when referring to stabilising stainless steels

• The ‘soak’ time

• The max. cooling rate

• If the item needs to be given any additional support

• The position of the thermocouples to monitor the width of heated

grain growth zone

Other Mechanical Properties

Typical Chemical Composition Typical Mechanical Properties (t=25mm)

WELDOX is a registered Trade Name of SSAB Oxelosund

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